Material Challenges in Developing a Sustainable Metal Processing Infrastructure - Workshop Report

Published

September 23, 2025

Author(s)

Andrew Iams, James Zuback, Mark Stoudt, Carelyn Campbell

Abstract

As metals and manufacturing industries continue to transition towards sustainable and circular principals, innovations are needed to address a variety of challenges. Multidisciplinary solutions are required across the materials lifecycle, from extraction, alloy design, manufacturing, reuse, and recycling. This special publication draws upon insights acquired from a NIST workshop held in July 2024 that convened experts from government, academia, and industry to identify challenges and opportunities for establishing a sustainable metals industry. The workshop emphasized the critical role of advanced extractive metallurgy, integrated computational materials engineering (ICME), and digital data infrastructures in accelerating the development of processing pathways and sustainable alloy design. Discussion about key materials systems included aluminum, steel, and critical materials. The workshop highlighted the necessity of redesigning alloys to tolerate higher impurity contents, developing energy-efficient extraction technologies, and optimizing process-structure-property relationships to enhance material performance. Molten oxide electrolysis for steelmaking, recovery of valuable elements from metallurgical waste streams, and alloy design for high-recycled-content aluminum die castings are examples of specific areas for investment that were identified. The aluminum and steel sectors were examined as critical case studies, each facing unique challenges for developing a sustainable processing infrastructure, recycling integration, and maintaining performance amid rising impurity levels. The role of sustainable manufacturing was underscored in the context of automotive applications, where life cycle assessment (LCA), high-volume closed-loop recycling, and new casting technologies are reshaping how metals are sourced and processed. Workforce development and educational revitalization emerged as essential enablers for ensuring that the U.S. maintains its capacity for innovation in extractive metallurgy and materials design. In summary, this document captures pathways toward a resilient and sustainable metals processing economy to meet future industry needs.

Citation

Special Publication (NIST SP) - 1500-32

Report Number

1500-32

NIST Pub Series

Special Publication (NIST SP)

Pub Type

NIST Pubs

Download Paper

https://doi.org/10.6028/NIST.SP.1500-32

Local Download

Keywords

Alloy Design, Circular Economy, Critical Materials, Extractive Metallurgy, Steel, Aluminum, Integrated Computational Materials Engineering, Life Cycle Assessment, Recycling, Sustainable Manufacturing.

Citation

Iams, A. , Zuback, J. , Stoudt, M. and Campbell, C. (2025), Material Challenges in Developing a Sustainable Metal Processing Infrastructure - Workshop Report, Special Publication (NIST SP), National Institute of Standards and Technology, Gaithersburg, MD, [online], https://doi.org/10.6028/NIST.SP.1500-32, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=960474 (Accessed September 25, 2025)